h

995
kg
m
3
:=
Q m
h
c
ph
T
h1
T
h2

( )
:= Q 5.225 10
6
W = T
c2
T
c1
Q
m
c
c
pc

+ := T
c2
286.463 K =
T
lmcf
T
h1
T
c2

( )
T
h2
T
c1

( )

ln
T
h1
T
c2

T
h2
T
c1

\
|
|

:= T
lmcf
17 K =
Two tube passes, therefore: CTP 0.9 := also from 90 degree layout CL 1 := N
p
2 :=
Assume velocity for tube side as: u
t
2
m
s
:= N
t
4 m
c

c
d
i
2
u
t

:= N
t
373.019 = take it as N
t
373 :=
Flow area : A
t
d
i
2

4
N
t
:= A
t
0.075m
2
=
ME421 HEAT EXCHANGER AND STEAM GENERATOR DESIGN
HOMEWORK 6 SOLUTION
FALL 2012
Start with the following design problem and Kern method solution. You are asked to complete detailed
shell side calculations (heat transfer and pressure drop) using Bell-Delaware method. Given procedure
step numbers match with the ones in thesis chapter 4.
Bonus (%30 extra): By changing flow rates form a table showing the sensitivity of the results to flowrate.
Design Problem:
Distilled water at a flow rate of 50 kg/s enters a baffled shell-and-tube heat exchanger at 40C and leaves at 15C.
The heat will be transferred to 150 kg/s raw water coming from a supply at 5C. You are requested to design a
shell-and-tube heat exchanger with an E-type shell and two tube passes for this purpose. The tube diameter is
(19 mm. O.D. with 16 mm I.D.) and tubes are laid out on 1 in. square pitch. Tube material conductivity is 50
W/m.K. Assume a total fouling resistance of 0.000176 m2K/W and baffle spacing of 500mm with 25% cut. There
is no limitation on percentage over surface. With an initial assumption of 2 m/s tube side velocity and using Kern
method, calculate:
Log-mean-temperature-difference(Tlm,cf), shell diameter(Ds), number of tubes per pass(Nt), tube side
fluid velocity(ut), tube and shell side heat transfer coefficients(ht and hs), clean and fouled overall heat transfer
coefficients(Uc and Uf), tube side pressure drop(pt) and heat exchanger length(L).
Perform a single iteration in correct order! Use Equation (8.7) for the shell diameter.
Note that your final design should have a geometry selected from Table 8.3.
Properties of raw water in tube side: cp,c=4190 J/kg.K Prc=8.2 c=12.0x10-4 N.s/m2
kc=0.59 W/m.K c=1000 kg/m3
Properties of distilled water in shell side: cp,h=4180 J/kg.K Prh=5.5 h=8.0x10-4N.s/m2
kh=0.62 W/m.K h=995 kg/m3
Solution :
We will start with the Kern Method solution, then we will develop the Bell-Deleware solution.
m
h
50
kg
s
:= m
c
150
kg
s
:= T
h1
40 273.15 + ( ) K := T
h2
15 273.15 + ( ) K := T
c1
5 273.15 + ( ) K :=
d
o
19 mm := d
i
16 mm := P
T
1 in :=
c
pc
4190
J
kg K
:= Pr
c
8.2 :=
c
12 10
4

N s
m
2
:= k
c
0.59
W
m K
:=
c
1000
kg
m
3
:=
c
ph
4180
J
kg K
:= Pr
h
5.5 :=
h
8 10
4

N s
m
2
:= k
h
0.62
W
m K
:=
A
s
D
s
NTC d
o

( )
B := A
s
0.099m
2
= G
s
m
h
A
s
:= G
s
504.032
kg
m
2
s
=
Re
s
G
s
D
e

h
:= Re
s
1.527 10
4
=
Assuming constant properties (due to small temperature differences):
Nu
s
0.36 Re
s
0.55
Pr
h
1
3
:= Nu
s
127.109 = h
s
Nu
s
k
h

D
e
:= h
s
3.252 10
3

W
m
2
K
=
Overall heat transfer coefficient : k
t
50
W
m K
:= R
ft
0.000176
m
2
K
W
:=
U
c
1
h
s
1
h
t
d
o
d
i
+
d
o
ln
d
o
d
i
|

\
|
|

2 k
t

+
|

\
|
|
|
|

1
:= U
c
2.096 10
3

W
m
2
K
=
U
f
1
U
c
R
ft
+
|

\
|
|

1
:= U
f
1.531 10
3

W
m
2
K
=
For the fouled case we determine the required area using correction factor obtained from Figure 2.7:
P
T
c2
T
c1

T
h1
T
c1

:= P 0.238 = R
T
h1
T
h2

T
c2
T
c1

:= R 3.007 = therefore ; F 0.8 :=

A
f
Q
U
f
F T
lmcf

:= A
f
250.959 m
2
=
Shell diameter : A
1
CL P
T
2
:= A
1
6.452 10
4
m
2
= D
s
4 N
t
N
p
A
1

CTP
:= D
s
0.825m =
D
s
32.487 in = When we round this to the smaller value in Table 8.3: Ds=31 in and Nt*Np=640 for 2-P obtained.
D
s
31 in := N
t
640
N
p
:= N
t
320 = with baffle spacing: B 500 mm :=
u
t
4 m
c

c
d
i
2
N
t

:= u
t
2.331
m
s
=
Re
t

c
u
t
d
i

c
:= Re
t
3.108 10
4
= f
t
1.58 ln Re
t
( )
3.28
( )
2
:= f
t
5.859 10
3
=
Nu
t
f
t
2
|

\
|
|

Re
t
Pr
c

1.07 12.7
f
t
2
|

\
|
|

0.5
Pr
c
2
3
1
|

\
|
|
|

+
:= Nu
t
234.983 = h
t
k
c
d
i
Nu
t
:= h
t
8.665 10
3

W
m
2
K
=
Shell side heat transfer :
D
e
4 P
T
2
d
o
2

\
|
|
|

d
o

:= D
e
0.024m = NTC
D
s
P
T
:= NTC 31 =
D
s
0.787m = N
p
2 =
Since temperature changes are low we do not need a pull through floting head therefore we don't need to use
sealing strips. So we have FX type inexpensive bundle construction.
From figure 4.11 of the thesis, diametral clearence for Lbmax < 900mm case considering drilled holes: L
tb
0.8mm :=
Using Eq (4.50) of the thesis for shell-to-baffle clearence: L
sb
3.1mm 0.004 D
s
+ :=
L
sb
6.25 10
3
m =
We have an FX type tube bundle so we need minimum shell diameter to tube bundle clearence, let us take it as
5 mm (an arbitrary small value by comparing with Lsb):
L
bb
5mm := therefore Dctl using Eq (4.52): D
ctl
D
s
L
bb
d
o
+
( )
:= D
ctl
0.763m =
D
otl
D
s
L
bb
:= D
otl
0.782m =
Shell side fluid is hot fluid, tube side fluid is cold fluid:
T
si
T
h1
:= T
so
T
h2
:= T
ti
T
c1
:= T
to
T
c2
:= m
s
m
h
:= m
t
m
c
:=

s

h
:= c
ps
c
ph
:= k
s
k
h
:=
s

h
:=

t

c
:= c
pt
c
pc
:=
Since temperature differences are small there is no need for temperature correction:
sw

s
:=
Therefore the exchanger length is:
L
A
f
N
p
N
t
d
o

:= L 6.569m =
Tube side pressure drop: p
t
4f
t

c
u
t
2

2L
d
i
:= p
t
5.23 10
4
Pa =
Bell - Deleware Method detailed shell side analysis:
Additional Bell-Delaware method definitions:
Tube wal l thickness: L
tw
d
o
d
i

( )
2
:= L
tw
1.5 10
3
m =
Tube l ayout characteri stic angle:
tp

2
:=
L
to
L := L
ts
0.1 D
s
:= L
ts
0.079m = therefore : L
ti
L
to
2L
ts
:= L
ti
6.412m =
L
tt
L
to
:=
Baffle cut : B
c
25% := Central baffle spacing: B 0.5m =
We can just take 11 central baffle spacing and divide the left over from L to inlet and outlet baffles:
B
i
L 11 B ( )
2
:= B
i
0.535m = B
o
B
i
:=
Assuming no impingement plates, therefore we can use previously fixed shell size and number of tubes:
N
t
320 =
T
m
F T
lmcf
:= T
m
13.6 K =
6 ) Total heat transfer surface of the exchanger: A
o
d
o
L N
t
N
p
:= A
o
250.959 m
2
=
7 ) Segmental baffle window calculations:

ds
2 acos 1 2 B
c

( )
:=
ds
120 deg =

ctl
2 acos
D
s
D
ctl
1 2B
c

( )

(
(

:=
ctl
117.909 deg =
8 ) Baffle window flow areas:
S
wg

4
D
s
2

ds
360deg
sin
ds
( )
2

\
|
|

:= S
wg
0.095m
2
=
F
w

ctl
360deg
sin
ctl
( )
2
:= F
w
0.187 =
F
c
1 2F
w
:= F
c
0.626 =
N
tw
N
t
N
p
F
w
:= N
tw
119.604 =
S
wt
N
tw

4
d
o
2

\
|
|

:= S
wt
0.034m
2
=
S
w
S
wg
S
wt
:=
S
w
0.061m
2
=
The cross flow area at the centerline of the shell for one cross flow between two bafflesA
s
0.099m
2
=
Bell-Deleware calculations:
1 ) Since we have 90 degree pitch: P
Teff
P
T
:=
Cross flow area from eq(4.53):
S
m
B L
bb
D
ctl
P
Teff
P
T
d
o

( )
+

(
(

:= S
m
0.099m
2
=
2 ) Average temperatures:
T
sav
1
2
T
si
T
so
+
( )
:= T
sav
300.65 K =
T
tav
1
2
T
ti
T
to
+
( )
:= T
tav
282.307 K =
3 ) Shell side Reynolds number
G
s
m
s
S
m
:= G
s
506.707
kg
m
2
s
= Re
s
d
o
G
s

s
:= Re
s
1.203 10
4
=
4 ) Shell side prandtl number
Pr
s
Pr
h
:= Pr
s
5.5 =
5 ) Mean temperature difference:
S
tb
0.013m
2
=
S
tb

4
d
o
L
tb
+
( )
2
d
o
2

(
(

N
t
N
p
1 F
w

( )
:=
14 ) Tube-to-baffle hole leakage area for one baffle
S
sb
5.153 10
3
m
2
= S
sb
D
s

L
sb
2
|

\
|
|

360deg
ds

360deg
|

\
|
|

:=
13 ) Shell-to-baffle leakage area
F
sbp
0.025 =
F
sbp
S
b
S
m
:=
S
m
0.099m
2
= S
b
2.5 10
3
m
2
=
S
b
B D
s
D
otl

( )
L
pl
+

:=
L
pl
0m :=
12 ) Bundle-to-shell bypass area parameters
N
b
12 := N
b
11.824 = N
b
L
ti
B
1 :=
11 ) Number of baffles
N
tcw
5.822 = N
tcw
2 L
wp

P
P
:=
L
wp
0.074m =
L
wp
0.4 D
s
B
c

D
s
D
ctl

\
|
|

:=
N
tcc
15.5 =
N
tcc
D
s
P
P
1 2 B
c

( )
:=
P
P
P
T
:= From Table 4.1 for 90 degrees :
10 ) Number of effective tube rows in cross flow
D
w
0.031m = D
w
4 S
w

d
o
N
tw
D
s

ds
360deg
+
:=
9 ) Equivalent hydraulic diameter of a segmental baffle window :
w
We assumed no sealing strips: N
ss
0 :=
r
ss
N
ss
N
tcc
:= r
ss
0 =
F
sbp
0.025 =
For turbulent flow: C
bh
1.25 := C
bp
3.7 :=
J
b
exp C
bh
F
sbp
1 2 r
ss

( )
1
3

(
(
(

(
(
(

:= J
b
0.969 =
R
b
exp C
bp
F
sbp
1 2 r
ss

( )
1
3

(
(
(

(
(
(

:= R
b
0.911 =
18 ) Heat transfer correction factor for adverse temperature gradient in laminar flow
N
c
N
tcc
N
tcw

( )
N
b
1 +
( )
:=
N
c
125.813 =
Since Res > 100 : J
r
1 :=
15 ) Segmental baffle window correction factor
F
c
0.626 = therefore J
c
0.55 0.72 F
c
+ := J
c
1.001 =
16 ) Correction factors for baffle leakage effects for heat transfer
r
lm
S
sb
S
tb
+
S
m
:= r
lm
0.181 =
r
s
S
sb
S
sb
S
tb
+
:= r
s
0.289 =
J
l
0.44 1 r
s

( )
1 0.44 1 r
s

( )

exp 2.2 r
lm

( )
+ := J
l
0.775 =
p 0.15 1 r
s
+
( )
0.8 +

:= p 0.607 =
R
l
exp 1.33 1 r
s
+
( )
r
lm
( )
p

:= R
l
0.545 =
17 ) Correction factors for bundle bypass effects for heat transfer
Re
s
1.197 10
4
=
From Table 4.2 at this Reynolds number and for 90 degree layout:
a
1
0.370 := a
2
0.395 := a
3
1.187 := a
4
0.370 :=
b
1
0.391 := b
2
0.148 := b
3
6.30 := b
4
0.378 :=
For Eqns (4.101) and (4.102) powers:
a
a
3
1 0.14 Re
s
a
4
+
:= a 0.215 = b
b
3
1 0.14 Re
s
b
4
+
:= b 1.073 =
Colburn j-factor and friction coefficient for ideal tube bank:
j
i
a
1
1.33
P
T
d
o
|

\
|
|
|
|

a
Re
s
a
2
:= j
i
9.054 10
3
=
f
i
b
1
1.33
P
T
d
o
|

\
|
|
|
|

b
Re
s
b
2
:= f
i
0.097 =
19 ) Heat transfer correction for unequal baffle spacing at inlet and/or outlet
L
i
B
i
B
:= L
i
1.069 = L
o
B
o
B
:= L
o
1.069 =
For turbulent flow : n 0.6 :=
J
s
N
b
1
( )
L
i
1 n
+ L
o
1 n
+
N
b
1
( )
L
i
+ L
o
+
:= J
s
0.994 =
20 ) Pressure drop correction for unequal baffle spacing at inlet and/or outlet
R
s
B
B
o
|

\
|
|

2 n
B
B
i
|

\
|
|

2 n
+ :=
R
s
1.821 =
Calculation of Shell-Side Heat Transfer Coefficient and Pressure Drop
J
c
1.001 = J
l
0.775 = J
b
0.969 = J
s
0.994 = J
r
1 =
For ideal heat transfer coefficient we need Colburn j factor for an ideal tube bank ( 90 degree). We can obtain
it from figures or in this case we can use the correlations in the thesis Eqns (4.101) and (4.102) together
with Table 4.2 for the coefficients.
Re
s
d
o
m
s

s
A
s

:=
p
s
1.346 10
4
Pa = p
s
p
c
p
w
+ p
e
+ := Total shell side pressure drop then :
p
e
1.767 10
3
Pa = p
e
p
bi
1
N
tcw
N
tcc
+
|

\
|
|

R
b
R
s
:=
c )
Note that there is no 10^-3, it is for correction from mm to m but we used m everywhere.
p
w
7.46 10
3
Pa = p
w
N
b
2 0.6 N
tcw
+
( )
m
w
2
2
s

(
(
(

R
l
:=
b ) For turbulent flow:
m
w
642.951
kg
m
2
s
= m
w
m
s
S
m
S
w

:=
p
c
4.229 10
3
Pa = p
c
p
bi
N
b
1
( )
R
l
R
b
:= a )
p
bi
774.954 Pa =
p
bi
4 f
i

G
s
2
2
s

sw

s
|

\
|
|
|

0.14
N
tcc
:=
G
s
506.707
kg
m
2
s
= Shell side pressure drop consists of three components:
h
s
4.629 10
3

W
m
2
K
= h
s
h
i
J
c
J
l
J
b
J
s
J
r

( )
:=
The shell side heat transfer coefficient:
h
i
6.203 10
3

W
m
2
K
= h
i
j
i
c
ps

m
s
A
s
|

\
|
|

k
s
c
ps

s

\
|
|

2
3

sw
|

\
|
|
|

0.14
:=
The ideal tube bank-based heat transfer coefficient from Eq (4.100):